Zero Carbon Systems

Direct air capture for CO2 removal

Process Modeling Engineer

Process EngineeringConfirmed live in the last 24 hours

Full-timeBrighton, CO, USA$145k - $165k /yr

About the Job

Requirements

A degree in Chemical Engineering or a related field is required.
At least 7 years of experience after an undergraduate degree is required, with the alternatives of a bachelor's degree plus 7 years, a master's degree plus 5 years, or a PhD plus 2 years.
Prior techno-economic analysis experience for highly integrated industrial processes is required.
Hands-on process engineering experience in an industrial setting or chemical manufacturing plant is required.
Knowledge of methods for representing and modeling heat and mass transfer in porous materials is required.
Proficiency with Excel, VBA, Python, JMP, or similar tools to maximize the functional utility of model outputs is required.
Strong analytical thinking, problem-solving, and troubleshooting skills are required.
Excellent communication, reporting, and presentation skills are required.

Responsibilities

Use and develop internal process modeling tools to guide operating-point selection for the demo and production facilities based on operating cost, capital cost, and energy efficiency.
Continuously update and refine process models based on design improvements, operational data, and material advances, including running and optimizing the Aspen Custom Modeler model.
Translate Aspen process models into an Excel output that generates system equipment lists, equipment sizing at maximum, minimum, and nominal levels, stream lists, pipe sizing, power demand, and stream tables; automate this output using VBA or similar tools to populate vendor-ready equipment specification sheets and run self-consistency checks.
Work with appropriate personnel to translate model outputs into Aspen Capital Cost Estimator and related cost estimation tools, and compare internal capital estimates against those generated by external design firms.
Use cost estimates and vendor quotes to specify equipment and area-basis costs, sizing basis, and scaling exponents for the larger system techno-economic analysis model, and develop shortcut models to support quick process review and analysis.
Partner with internal drafters and designers to keep Process Flow Diagrams and Piping and Instrumentation Diagrams aligned with the latest process model, and communicate model, process, and equipment updates to the external engineering design firm.
Ensure design and equipment updates are integrated into the demo facility design and build, and use experience and vendor interactions to inform equipment selection and relative pricing to reduce capital cost and increase process efficiency.
Identify opportunities to reduce system energy, capital expenditure, and operating expenditure through process design optimization and techno-economic analysis; work with domain leads in materials, site operations, and mechanical engineering to scope projects that test opportunities and incorporate findings into the model.
Collaborate with engineering, research and development, and project management to integrate process models and cost data into project workflows, identify critical impact variables and data quality gaps, and support Life Cycle Analysis and environmental impact assessments.
Present model findings, cost estimates, and process updates to senior leadership, investors, and other stakeholders.

Desired Qualifications

A graduate degree is preferred.
Process operations or design exposure, including demonstrated experience reading and generating Process Flow Diagrams, Piping and Instrumentation Diagrams, equipment lists, and instrument lists, is preferred.
Experience with detailed design and equipment selection or procurement is preferred.
Experience working with cross-functional teams, scoping new research and development or engineering projects, and working at a startup moving from research and development to testing and scale-up is preferred.
Experience communicating complex numerical results to a non-technical audience is preferred.

Salary Range: 145000 to 165000 (Currency: USD) (Pay period: per-year-salary)

About Zero Carbon Systems

Zero Carbon Systems (ZCS) is a clean energy and direct air capture company on a mission to accelerate the transition to a zero carbon future. We are developing and deploying breakthrough technologies designed to reduce atmospheric CO2 at scale, addressing one of the most pressing challenges of our time.

Backed by mission aligned investors and led by a team of passionate innovators, ZCS sits at the intersection of cutting edge science and real world impact. We are building a diverse, collaborative, and driven team of individuals who share our commitment to excellence, creativity, and the belief that the work we do today will shape the world of tomorrow.

If you are energized by meaningful work and want to be part of a company where your contributions directly advance the clean energy transition, we would love to hear from you.

Position Overview

Zero Carbon Systems seeks a Process Modeling Engineer to bridge theoretical modeling, process design, and plant operations, leveraging our internal process and equipment models to develop a highly rigorous techno-economic analysis (TEA) that our leadership team will use to finalize operating points for the ZCS demo and production facilities. Using existing heat and mass balances and capital estimates, this engineer will optimize the process across scenarios such as weather, location, and plant configuration, improve process design through research and design review, and sharpen capital estimates through direct vendor feedback and informed equipment selection. The ideal candidate will have strong TEA experience for highly integrated industrial processes, hands-on process engineering experience in an industrial setting, and the ability to communicate complex numerical results clearly to leadership, investors, and external reviewers. This full-time position can be based in Brighton, Colorado or performed remotely, and reports to the Process Modeling Lead.

Responsibilities Include:

Use and develop internal process modeling tools to guide the selection of operating points for the ZCS demo and production facilities based on operating cost, capital cost, and energy efficiency
Continuously update and refine ZCS process models based on design improvements, operational data, and material advances, including running and optimizing our Aspen Custom Modeler (ACM) model
Translate Aspen process models into an Excel output that generates the system equipment list, equipment sizing (max/min/nominal), stream list, pipe sizing, power demand, and stream tables, and automate it using VBA or similar tools to rapidly populate vendor-ready equipment specification sheets and run self-consistency checks
Work with appropriate personnel to translate model outputs into Aspen Capital Cost Estimator (ACCE) and related cost estimation tools, and diligently compare internal capital estimates against those generated by external design firms
Use ACCE estimates and vendor quotes to specify equipment and area basis costs, sizing basis, and scaling exponents for the larger system TEA model, and develop shortcut models to support quick process review and analysis
Partner with internal drafters and designers to keep Process Flow Diagrams (PFDs) and Piping and Instrumentation Diagrams (P&IDs) aligned with the latest process model, and communicate model, process, and equipment updates to our external engineering design firm
Ensure all design and equipment updates are integrated into the demo facility design and build, and provide insight from experience and vendor interactions on equipment selection and relative pricing to drive down capital cost and increase process efficiency
Identify opportunities to reduce system energy, CapEx, and OpEx through fundamental process design optimization and rigorous TEA, working with domain leads in materials, site operations, and mechanical engineering to scope projects that test those opportunities and translate findings back into the model
Collaborate with engineering, R&D, and project management to integrate process models and cost data into larger project workflows, identify critical impact variables and data quality gaps, and support Life Cycle Analysis and environmental impact assessments
Present model findings, cost estimates, and process updates to senior leadership, investors, and other stakeholders

Requirements Include:

Degree in chemical engineering or a related field; graduate degree preferred
7+ years of experience post undergraduate degree (BS + 7 years, MS + 5 years, or PhD + 2 years)
Prior TEA experience for highly integrated industrial processes
Prior hands-on process engineering experience in an industrial setting or chemical manufacturing plant
Knowledge of methods for representing and modeling heat and mass transfer in porous materials
Proficiency with Excel, VBA, Python, JMP, or similar tools to maximize the functional utility of model outputs
Strong analytical thinking, problem solving, and troubleshooting skills, with excellent communication, reporting, and presentation skills
Preferred: process operations and/or design exposure, with demonstrated experience reading and generating PFDs, P&IDs, equipment lists, and instrument lists
Preferred: experience with detailed design and equipment selection or procurement
Preferred: experience working with cross-functional teams, scoping new R&D or engineering projects, and working at a startup moving from R&D to testing and scale-up
Preferred: experience communicating complex numerical results to a non-technical audience

Zero Carbon Systems is proud to be an Equal Opportunity Employer
All qualified applicants will receive consideration for employment without regard to race, color, religion, sex, national origin, disability, protected veteran status, or any other characteristic protected by law.

Your Right to Work
In compliance with federal law, all persons hired will be required to verify identity and eligibility to work in the United States and to complete the required employment eligibility verification document form upon hire.

About the Company

Zero Carbon Systems

Direct air capture for CO2 removal

Zero Carbon Systems captures CO2 from ambient air using direct air capture technology and designs its systems for megaton-scale removal. Its process is continuous and can run entirely on renewable electricity, with very large, high-throughput units to reduce costs. The company leverages a decade of related technology from Global Thermostat and focuses on continuous operation, renewable power, and large-scale hardware to optimize economics. Its goal is to remove at least 0.5 gigatons of CO₂ per year from the atmosphere by 2050.

Company size: Not listed
Company stage: Not listed
Total funding: Not listed
Headquarters: New York City, New York
Founded: 2020

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